MachineWorlds new algorithm allows more flexible quality optimization in milling processes, which enhances finishing surface accuracy and performance in terms CPU time and number of faces of the stock after simulation.

MachineWorks Ltd. will introduce Version 7.4 of its CNC simulation/verification software at EMO Milano 2015, a new program it said has been written to address the greatest software challenges for developers of CAM products and manufacturers of CNC controllers and machine tools. Among the new features, it said this version simulates results for “much improved surface quality and much greater accuracy.”

"This is not just another release," stated MachineWorks’ sales and marketing director, Mike Nicholson. "Years of research have made possible some of the advances that we can see today in 7.4, like for example a completely new approach to five-axis simulation that provides a real leap forward."

MachineWorks explains the result of the research as “a new method to resolve an old problem.” A new algorithm for five-axis swept volume generation allows more flexible quality optimization, which enhances the finishing surface accuracy. Meanwhile, the developers took up the challenge of looking into five-axis simulation, analyzing every known technique, and then proposing a solution from a completely different perspective.

After years of developing and testing the result is a new algorithm for five-axis, swept volume generation. One of the improvements that will benefit programmers is fixing the dome effect created by conventional simulation approaches, resulting in better and more accurate program performance.

When milling an impeller, scalloping can occur — and that constitutes another major issue with the accuracy of the surfaces. The new algorithm tackles this problem effectively because of its capability to achieve much more accurate five-axis swept volumes. The new five-axis swept volume method allows more flexible quality optimization, which enhances the finishing surface accuracy and performance in terms CPU time and number of faces of the stock after simulation.

"A dedicated team of developers invested several years creating a more efficient method that would resolve satisfactorily the most common five-axis simulation challenges. We are pleased to announce today that the fruits of our research will be included in the up-coming release," according to Dr. Fenqiang Lin, chief technology officer.

Version 7.4’s new sampling technology creates images with improved surface detail, even on close ups, so programmers have a highly accurate, graphic representation of their projects, at all times.

The developers also noted that the new version of the program simulates both additive and subtractive processes in a single CNC environment. “MachineWorks can deliver a seamless simulation for both the material deposition and the material removal as part of the machining steps of the hybrid manufacturing process,” the developer announced.